Just-in-time Supply Chain Flow Kaizen Workshop
(5 days)

Overview | Description | Example Agenda | On-site Coaching Available

Overview top
Discover how to analyze your supply chain value stream, "see" its shortfalls, and apply lean principles and methods to significantly improve flow, decrease lead time, and reduce costs

Description top
  • Discuss just-in-time supply chain logistics principles, value, and value streams
  • Create a comprehensive current state value stream map of the company's "focus" dock-to-point of use (POU) supply chain value stream
  • Using actual case studies and team interactions, thoroughly analyze a product fabrication, a vehicle assembly, and a machine fabrication manufacturer from the last value adding step at the upstream supplier, through internal facility material management activities, to the material's point of use
  • Discuss key aspects of just-in-time supply chain operations, smoothed & balanced workload, visual process control, and flow kaizen principles and methodologies
  • Assist kaizen team members  in understanding how JIT principles & methods can significantly improve materials flow within the "focus" supply chain value stream
  • Assist team members in visualizing, then designing an aggressive, feasible future state improvement design and an aggressive transformation plan
  • Discuss effective techniques to manage a complete value stream and transform it to just-in-time principles and practices

To achieve these objectives, participants will:

  • Practice, through discussions and case study illustration, just-in-time supply chain value stream flow mapping, logistics kaizen concepts, team building, and kaizen management
  • Develop current and future state maps of ta slice of the company's actual supply chain value streams
  • Identify flow impediments which must be eliminated through process kaizen to achieve the future state improvements and discuss mechanisms which support implementation

An enterprise product's value stream includes all actions to acquire materials, add value to make products, sell them, then ship them to customers.

Each action in this chain of activities is either value adding (e.g., being fabricated) or non-value adding (e.g., being transported). "Seeing" your supply chain's processes from an "extended" value stream perspective means looking at the total system, not just a component. It means paying attention to improving the system as a whole, supplier to customer, rather than focusing on improving only an individual sub-component of the system.

By creating an "extended" current state map (where we are now) you create a "visual" of supply chain systems flow.  From this baseline, you can apply lean principles to create an improved future state (where we want to be) vision of an ideal just-in-time logistics value flow.

Just-in-time supply chain flow kaizen is a straightforward process. You map the extended system along a representative slice of the supply chain's flow, design improvements through application of lean principles, then document your improvement vision by designing a future state map of the improved flow.

The results will be eye opening, revealing supply chain conditions and opportunities which might otherwise go unnoticed.

Example Agenda top

Day 1: Supply Chain Value Stream

Lean Flow Fundamentals
Conventional Supply Fundamentals
World Class Logistics
Just-in-time Supply Chain Fundamentals
Value & Value Streams
Base-lining Materials Activities
Known Supply Impediments
Traditional Supply Chain Operations
Value Stream Mapping Process
Dock-to-POU Value Stream Mapping
Dock-to-POU Case Study Examples
Supply Chain Value Stream Mapping
Cross-functional Mapping
Team Current State Mapping

Day 2: Current State Supply Value Stream Mapping

Team  Dock-to-POU Current State Process Assessment
Team Dock-to-POU Current State Map Development
Team Dock-to-POU Current State Map Presentations
Group Dock-to-POU Current State Map Consolidation
Group Current State Map Opportunities
Group Final Dock-to-Dock Current State Business Process Design
JIT Supply Chain Principles & Methods
  - Smoothing Requirements
  - Orchestrating Flow
  - Enhancing Flow
  - Activity Cell Design
  - Visual Process Control
2nd Day Progress Wrap-Up

Day 3: Just-in-time Supply Chain

JIT Supply Chain Principles & Methods
  - Continuous Flow
  - Pull Systems
JIT Facilities Design
  - JIT Transportation
  - JIT Material Handling
Improving Flow thru JIT
  - Integrating MRP into JIT
  - Feeder Activity Synchronization
  - Inter-Facility Material Management
  - Synchronizing Activities
  - Synchronizing Supplier Coordination
Just-in-time WIP Flow Demonstration
Dock-to-Dock Future State Mapping
Future State Case Studies
Supply Chain Future State Mapping
Team Dock-to-Dock Future State Process Improvement Assessment
3rd Day Progress Wrap-Up

Day 4: Inventing a Better Future State Flow

Team Dock-to-Dock Process Improvement Assessment (Con't)
Team Dock-to-Dock Future State Mapping
Team Dock-to-Dock Future State Map Presentations
Group Dock-to-Dock Future State Map Consolidation
4th Day Progress Wrap-Up

Day 5: Becoming Lean

Group Dock-to-Dock Future State Opportunities Discussions
Group Dock-to-Dock Final Future State Map Design
Group JIT Future State Supply Chain Impediments
Future State Performance Metric Discussions
Becoming Lean
JIT Supply Chain Future State Transformation Planning
Wrap-Up & Workshop's Value

On-site Coaching Available top
To request this on-site Just-in-time Supply Chain Flow Kaizen Workshop, please contact Jim Price at (502) 570-2766 or (859) 351-3215 (mobile) or via email: .